Fabric construction and method of making



March 14,1939. 5 H, FOSTER 2,150,652

FABRIC CONSTRUCTION AND METHOD OF MAKING Filed Jan. 12, 1937 INVENTOR.Zowlwefl flf'bazfei- I} I BYWFW ATTORNEY.

Patented Mar. 14, 939

FABRIC CONSTRUCTION AND METHOD OF MAKING Boutwell H. Foster, Maplewood,N. J., assignor, by

mesne assignments, to United States Rubber Company, New York, N. Y., acorporation of New Jersey Application January 12, 1937, SerialNo.'120,237

Claims.

This invention relates to a fabric construction and the method of makingthe same, more par ticularly to a fabric construction of increasedwearing qualities.

In the usual types of textile fabrics ordinary wear or abrasion must beborne by those projecting portions of the yarns composing them which areexposed or appear at the fabric surface. Hence in such fabrics the sameyarns, whether singles, plied or cabled, must serve the double functionof providing tensile strength for the fabric and resisting abrasivewear, with the result that as the fibers are worn through, the yarnsbecome weakened and the strength of the fabric itself suffers. I

An object of the present invention ist'o provide a textile fabric withimproved wearing qualities.

Another object is to provide such a fabric in which yarn embodiedtherein is protected against wear by a long-wearing covering.

Another object is to provide a woven fabric in which one or both of thewarp and weft are protected against Wear by a textile covering havingoutwardly directed fiber ends.

Still another object is to provide a method for producing the fabric. 7

Other objects will appear from the appended specification and drawing,in which latter:

Figure 1 is a broken away plan view, on an enlarged scale, of a fabricembodying the invention;

Figure 2 is a section on the line 2-2 of Fig. 1;

Figure 3'is a similar section to Fig; 2 but showing the fabric at alater stage; and

Figure 4 is a view similar to Fig. 3, butslightly modified.

In carrying out the invention a'core yarn is provided, which may be ofthe size ordinarily used in making fabrics of the character desired, orit may be of slightly smaller gauge,and in either case being ofsubstantial body and strength. This core yarn is then closely helicallywrapped with a relatively firmly twisted covering yarn, which yarnpreferably is of smaller gauge. The covering yarn may consist of asingle end, but for speed and economy there may be used instead aplurality of ends wound on in parallel.

The covered core yarn is then incorporated in the desired fabric in suchmanner as to dispose its covering yarn on one or both surfaces of thefabric, that is, so that the covering yarn will take the wear orabrasion caused by ordinary use. As the exposed surface of the coveringyarn is subjected to wear or use, the fibers of the yarn are worn orrubbed through at their sides until ultimately the covering yarn issevered, and when this occurs the severed ends of the covering yarnuntwist and straighten so that the severed fiber ends extend in agenerally outward direction while the blghts of the severed fibersremain anchored in the fabric, thus producing on the face of the fabrica short pile effect. Wear on the fabric as a whole will thereafter beapplied only to the ends of the severed fibers, and the core yarn willbe protected, remaining intact. It follows that the fabric produced ispossessed of greatly improved long-wearing qualities.

Insteadof depending upon wear in use to cause severing and fraying ofthe covering yarn, the fabric may be at once superficially treated insuch a manner as to cause severing and fraying of the covering yarn, asby running the fabric over a revolving sand roll, or through a nappingor shearing machine.

In either case it is seen that abrasive wear upon the surface results inno decrease in the strength ofthe fabric, since the tensilestress-resisting core yarns remain intact.

Either the core yarn or the yarn used for wrapping the core, or both,can be single, plied or cable twisted or any combination thereof. Eitherthe core or its wrapping yarns can be made of any suitable textilematerials, such as cotton, wool, silk, rayon, asbestos, glass, or any ofthe bast fibers such as flax, jute, hemp, ramie, sisal, etc. The coveredyarn may be applied to the making of any of the usual textile fabricswhere it is desired to have an increased wear surface, such as knittedor woven fabrics. -In the case of woven fabrics, the covered yarn may beused in either the warp or weft or in both warp and. weft.

In the case where the fabric is not firmly woven, it will be necessaryto use an adhesive to prevent displacement or removal of the fibers ofthe covering yarn, after such yarn has been severed either by use or byan abrading or tearingtreatment. Any suitable material, such as rubberlatex, aqueous dispersions of rubber, glue, starch, gums, resin, etc.,may be used as the adhesive. In the case where the fabric is to beprovided with the wear resisting surface on one side only, the fibersmay be held in place by applying the adhesive to the other side or backof the fabric. Instead of applying the adhesive to the back, it may beapplied to the core yarn either at the time of applying the coveringyarn or prevlously-' thereto, and it will be necessary to use thislatter method of applying the adhesive to the core of the covered yarnin cases where the wear resisting surface is to be provided on bothsides of the fabric.

Referring to the accompanying drawing, illustrating as one embodimentthe application of the invention to a woven fabric, the numeral 1designates the fabric generally, the warp yarn is designated 2, and itscore 3, the latter consisting of three yarns 4. In the embodiment shown,the helical covering 5 consists of three ends 6 of relatively finergauge yarn, which should be firmly twisted, and the covering should beclosely and compactly applied, that is, with a short pit-ch. At 1 thereis shown the weft or filling yarn, which in the present case is ofsmaller gauge, so that the crimps of the covered warp yarn will beexposed atboth surfaces of the fabric.

In Fig. 2 there is shown a section of the fabric after weaving, and asbefore pointed out, this fabric may then be applied to various purposes,and in use wear or abrasion will in time sever the fibers and yarns ofthe covering yarn so that the severed yarn ends will untwist and springaway from the core yarn and form small tufts of fibers, the ends ofwhich fibersproject generally outwardly from the fabric surface. In thismanner the fiber ends will take the ordinary wear or abrasion and thusgreatly prolong the life of the fabric. As before pointed out, thesevering and untwisting of the yarns of the covering may be produced bysanding or by otherwise abrading the fabric surface. In Fig. 3 there isshown a fabric with cover yarn frayed on one side, while Fig. 4 shows aslightly modified form in which ordinary wear or intentional abrasionhas severed and frayed out the yarn ends of the covering on both sidesof the fabric.

The following are specific examples of the application of the invention:

EXAMPLE I Covered yarnall cotton C0re. lfi's/Ii (17.9 S or left-handtwist). Wrapping yarn 3 ends of 36's single.

Wrappings per inch 32.6 (Z or right-hand wind). Length of wrapping v. nto cover 1 yd. of core yarn R6. 5 inches. Wei ht distribution:

Core 48.5%. (over 51.5%.

Fabric construction-41 cotton Ends per inch (covered yarn) 39.

Picks per inch 20.5. Warp yarn 16/3 core, covered with Ii3fis/l. Fillingynrn 21/3 (16.2 S or left-hand twist). Gauge fabric .0375 inch. Weight.ozs./s .yd 14.1. Strength-warp (1" 3 grab test) 83 lbs. Strcngthfilling(1 x 3 grab test) 76lbs.

EXAMPLE II Covered yarn (cotton core, worsted coverzng) Core yarn 18's/3cotton (11 S twist). Wrapping yarn 3 ends of 1/458 worsted. 'Wrappingsper inch 29.4 (S).

Length oi wrapping yarn to cover 1 yd. of core yarn 86.5 inches. Weightdistribution:

Core 44.3%. Cover 55.7%.

Fabrzc Ends per inch (covered yarn) 43.

Picks per inch 22.

\Varp yarn Worsted-covered cotton as dedescribed above.

22s/3 (18S twist).

.036 inch.

Stgength-avnrp (1" x 3 grab St Strengthfilling (1" x 3" grab test)Filling yarn 83 lbs.

It will be seen that by the invention a greatly improved wearingproperty can be imparted to fabrics of varied construction andmaterials. These fabrics may be of a character suitable for use assheetings, table cloths, shirtings, suitings.

ducks, etc. As an example, one suitable application is for the making offabric uppers of fabric and rubber footwear, such as tennis or outingshoes. In such footwear, difficulty has been had in obtaining a balancedconstruction, i. e., one in which the fabric upper will have a longerlife more closely approximating that of the rubber sole. The fabric ofthe present invention is a copsiderable advance in attaining the abovedesired end. The invention may also be applied in the making of coarserfabrics such as for use as rugs, carpets, mats, etc.

While a specific embodiment of the invention has been shown anddescribed, it is obvious that modifications may be made therein, and itis not desired to limit the invention otherwise than as set forth in theappended claims and as required by the prior art.

Having thus described my invention, what I claim and desire to protectby Letters Patent is:

1. The method of making a textile fabric which comprises covering atextile core yarn with a firmly twisted yarn arranged in closelyhelically disposed turns of low pitch, incorporating said covered yarnin a textile fabric with its cover exposed to surface wear, and breakingthe fibers of said yarn covering and outwardly directing the brokenfiber ends.

2. The method of making a textile fabric which comprises covering atextile core yarn with a finer gauge firmly twisted yarn arranged inclosely helically disposed turns of low pitch, incorporating saidcovered yarn in at least one of the warp or weft of a woven fabric withits cover exposed to surface wear, and severing fibers of said yarncovering and outwarly directing the severed fiber ends.

3. The method' of making a textile fabric which comprises covering atextile core yarn of at least moderate twist and substantial strengthwith a plurality of ends of a finer gauge firmly twisted yarn arrangedin closely helically disposed turns of low pitch, incorporating saidcovcred yarn in at least one of the warp or weft of a woven fabric withits cover exposed to surface wear, and superficially treating saidfabric to dispose loosened fiber ends of said covering yarn outwardly ofthe fabric surface.

4. The method of making a textile fabric which comprises covering atextile core yarn with a twisted yarn arranged in closely helicallydisposed turns of low pitch, incorporating said covered yarn in atextile fabric with its cover exposed to surface wear, loosening andoutwardly directing fiber ends of said covering yarn to thereby form awear resisting layer on the fabric, and anchoring the fibers of saidlayer in the body of the fabric by an adhesive.

5. The method of making a textile fabric which comprises covering atextile core yarn with a twisted yarn arranged in closely helicallydisposed turns and uniting said yarns by an adhesive, incorporating saidcovered yarn in a textile fabric with its cover exposed to surface wear,and loosening and outwardly directing fiber ends of said covering yarnon each side of the fabric.

6. A textile fabric having incorporated therein a yarn having a textilecore and a closely helically wrapped covering of firmly twisted textilefibers exposed on the fabric surface, portions of which covering fibershave severed free ends directed outwardly from the fabric surface.

7. A textile fabric having incorporated therein a yarn having a twistedtextile core and a closely helically wrapped covering of a plurality ofends of firmly twisted textile yarn of finer gauge exposed on the fabricsurface, a part of the fibers of said covering textile yarns havingsevered free ends directed outwardly from the fabric surface.

8. A textile fabric having incorporated therein a yarn having a twistedtextile core and a closely helically wrapped covering of twisted textilefibers exposed on the fabric surface, and an adhesive disposedinteriorly of the fabric and securing said fibers against removal.

9. A textile fabric having incorporated therein a yarn having a twistedtextile core yarn and a closely helically wrapped covering of firmlytwisted textile fibers, and an interposed adhesive securing said fibersto saidcore, a part of the fibers of said covering having free endsdirected outwardly from the fabric surface.

10. A woven textile fabric including in at least one of its warp or wefta yarn having a twisted textile core and a closely helically wrappedcovering of firmly twisted textile fibers, and an adhesive securing saidfibers against removal, a part of the fibers of said covering havingfree ends directed outwardly from each surface of the fabric.

BOUTWELL H. FOSTER.

